Biodegradable packaging component

ABSTRACT

An example packaging component according to the present invention includes a first compressible portion and a second compressible portion. The first portion is configured to be compressed onto a first side of a component to conform to a surface geometry of the component, and the second portion configured to be compressed onto a second side of a component opposite the first side to conform to the surface geometry of the component. The first and second portions are configured to be bonded to one another in a bonded region without bonding to the component. An example packaged component and method of packaging a component are also disclosed.

CROSS-REFERENCED TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application No.62/416,272, which was filed on Nov. 2, 2016.

BACKGROUND

Components such as automotive components are frequently shipped from afirst location to a second location. During shipping, the components areprotected by packaging materials. The packaging materials can beattached to the components. Such attaching can include the use ofadhesives, for example. After being shipped, the packaging materials areremoved from the component. Sometimes, this removal step damages thecomponent or requires additional post processing, such as removing theadhesives used to attach the packaging material to the component.

SUMMARY

An example packaging component according to the present inventionincludes a first compressible portion and a second compressible portion.The first portion is configured to be compressed onto a first side of acomponent to conform to a surface geometry of the component, and thesecond portion configured to be compressed onto a second side of acomponent opposite the first side to conform to the surface geometry ofthe component. The first and second portions are configured to be bondedto one another in a bonded region without bonding to the component.

An example packaged component according to an embodiment of the presentdisclosure includes a component and a packing component configured to atleast partially surround the component. The packing component comprisesa first portion configured to be compressed onto a first side of thecomponent and conform to a surface geometry of the component and asecond portion configured to be compressed onto a second side of thecomponent opposite the first side and conform to the surface geometry ofthe component. The first and second portions are bonded to one anotherin a bonded region without bonding to the component.

An example method of packaging a component according to the presentincludes compressing a first portion of a packing component onto a firstside of a component, compressing a second portion of a packing componentonto a second side of the component, the second side opposite the firstside, and bonding the first portion to the second portion in a bondedarea such that neither the first portion nor the second portion arebonded to the component.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A schematically illustrates a packaged component.

FIG. 1B schematically illustrates a section of the packaged component ofFIG. 1A.

FIG. 1C schematically illustrates an exploded view of the packagedcomponent of FIG. 1B.

FIG. 1D schematically illustrates an alternate packaged component.

FIG. 2 schematically illustrates an alternate packaged component.

DETAILED DESCRIPTION

Referring to FIGS. 1A-D, an example packaged component 8 is shown. Thepackaged component 8 includes a component 10 and packing components 12.In the example of FIGS. 1A and 1D, the component 10 is generallyrectangular and is fitted with multiple generally oversized rectangularor triangular packaging components 12 at its four corners, respectively.Packaging components 12 allow for a variety of sizes of component 10 tobe packaged in the same carton. However, it should be understood thatany number or configuration of packaging components 12 may be used. Itshould also be understood that the packaged component 8 can be anyshape, as can the packaging components 12. For instance, packagingcomponents 112 can be at one or more edges of the component 10, as shownin FIG. 2. Packaging components 12, 112 protect component 10 duringshipment or handling by, for instance, preventing component 10 frommoving or jostling. For simplicity, the below description referencesonly packaging components 12. However, it should be understood that thebelow discussion applies to packaging components 112 as well.

In an example packed component 8, packaging components 12 capture morethan 25% of the perimeter and less than 50% of the surface area of thecomponent 10. In another example, packaging components 12 capture morethan 50% of the perimeter and the surface area of the component 10.

The component 10 could be any object, such as an object being shipped orhandled. In one example, the component 10 is an automotive component,such as a windshield, a sheet metal stamping, or an assembled part likea hood or door. In a further example, the object includes a “Class A”surface that cannot be damaged or scratched during handling or shipping.Alternatively, the components could be any glass, metallic, polymeric,or ceramic object, including but not limited to bed backboards, plateglass, picture frames, etc.

The packaging components 12 comprise a compressible material. In oneexample, the compressible material includes some degree of porosity, orcavitation. A higher degree of porosity/cavitation generally correlateswith increased compressibility. Porosity/cavitation allows forcompressibility by the collapsing of voids that occurs when the materialis placed under pressure, and also provides softness to the material. Inone example, the compressible material can compress more than 30% of itsthickness due to lack of stiffness of the material or to voids or pores.Such compressible material can be used for thicker components 10. Inanother example, packaging material that can compress less than 30% ofits thickness due to material stiffness or lack voids or pores can besufficient for thinner components 10.

Referring to FIG. 1B, a section of the packaged component 8 of FIG. 1Ais shown. FIG. 1C shows an exploded view of the packaged component 8.The packaging components 12 each include a first portion 12 a and asecond portion 12 b, which are arranged on opposite sides 11 a, 11 b ofthe component 10, respectively. Portions 12 a, 12 b of packagingcomponents 12 are compressed onto sides 11 a, 11 b, respectively, suchthat the portions 12 a, 12 b conform to the edges and surface geometryof the component 10. In the example of FIG. 1C, neither of portions 12a, 12 b have any kind of cutouts or spaces formed to receive thecomponent 10. However, in another example, either one or both of theportions 12 a, 12 b can have cutouts or spaces formed to receive thecomponent 10 prior to being compressed around component 10.

The portions 12 a, 12 b are bonded together in a bonded region 16. Inone example, portions 12 a, 12 b are not bonded to one another in anyregion aside from the bonded region 16. That is, the portions 12 a, 12 bare bonded to one another, but not to the component 10. Therefore, thecomponent 10 is easily removed from the packaging component 12, withoutdamaging the component 10. Furthermore, no post-shipment processing,such as removing an adhesive from the component 10, is required.

In the example of FIGS. 1A-C, the portions 12 a, 12 b are bondedtogether with an adhesive 14. The adhesive 14 can be applied onto one orboth portions 12 a, 12 b. The adhesive 14 adheres to the portions 12 a,12 b but not to the component 10 to form the bonded regions 16. That is,the adhesive 14 adheres to the material of the portions 12 a, 12 b butdoes not adhere to the material of the component 10. The adhesive 14 caninclude, for instance, a water based glue, hot-melt, or a non-scratchingrubber latex. In one example, the adhesive 14 is a drypressure-sensitive adhesive commonly known as a press seal adhesive. Inanother example, the adhesive 14 could have some tack but not enough toadhere to component 10.

Additionally or alternatively to the adhesive 14, in another example,the portions 12 a, 12 b can be joined together in another manner, suchas by mechanical interlocking using a tongue and groove configuration,thermal fusing such as heat staking, or chemical bonding afforded byusing a room temperature cured adhesive applied to the portions 12 a or12 b, or to the outside the perimeter of component 10.

The compressible material can be a biodegradable material such as astarch-based biodegradable material in the form of a solid homogenoussheet, a convoluted sheet, or a sheet made up from fused pellets bondedtogether with a variation of voids or interstitial spaces. Thestarch-based biodegradable material may include, for instance, cornstarch or another type of processed or reclaimed starch. In one example,the starch-based material is dissolvable in water. In another example,the biodegradable material is formed of a corn-based cellulosic material(“greencell”) or other cellulose based material. In another example, thebiodegradable material is formed by providing starch flour with highamylose content and mixing the starch flour with water and additives.However, any biodegradable material may be used. ASTM Internationaldefines testing methods for determining whether a material is consideredto be biodegradable.

In one example, the amylose content of the starch-based biodegradablematerial may be greater than 40% by weight. More particularly, theamylose content may be between 55% and 75% by weight. The amylose actsas a blowing agent which allows the starch-based biodegradable materialto expand during processing to create a cavitated foam-like material. Inone example, the starch-based biodegradable material is expanded duringextrusion to form pellets, and the pellets can be loosely packedtogether or attached to one another with an adhesive such as one of theadhesives described above, or by fusing the pellets together with heat.In a further example, a material such as a heat-expandable thermoplasticmaterial is added to the biodegradable material in an extruder, orbefore the biodegradable material is dispensed in the extruder, toenhance properties of the extruded biodegradable material. Spacesbetween pellets or within each pellet can provide pores or voids whichallow the material to be compressed, as described above.

In another example, the compressible virgin or scrap material isshredded paper, corn husks, cotton or wool and an adhesive such as oneof the adhesives described above.

Although a preferred embodiment of this disclosure has been disclosed, aworker of ordinary skill in this art would recognize that certainmodifications would come within the scope of this disclosure. For thatreason, the following claims should be studied to determine the truescope and content of this disclosure.

What is claimed is:
 1. A packaging component, comprising: a firstcompressible portion and a second compressible portion, the firstcompressible portion configured to be compressed onto a first side of acomponent to conform to a surface geometry of the component and thesecond compressible portion configured to be compressed onto a secondside of a component opposite the first side to conform to the surfacegeometry of the component, wherein the first and second portions areconfigured to be bonded to one another in a bonded region withoutbonding to the component.
 2. The packaging component of claim 1, whereinthe first and second portions are bonded to one another by an adhesive.3. The packaging component of claim 2, wherein the adhesive includes atleast one of water based glue, hot-melt, non-scratching rubber latex,and dry pressure-sensitive adhesive.
 4. The packaging component of claim1, wherein the first and second portions are bonded to one another bythermal or chemical bonding.
 5. The packaging component of claim 1,wherein the first and second component are bonded to one another by atongue and groove configuration.
 6. The packaging component of claim 1,wherein the first and second portions comprise a starch-basedbiodegradable material having an amylose content of more than 40% byweight.
 7. The packaging component of claim 1, wherein the first andsecond portions comprise a material having pores or cavities, the poresor cavities providing compressibility to the material.
 8. A packagedcomponent comprising: a component; a packing component configured to atleast partially surround the component, the packing component comprisinga first portion configured to be compressed onto a first side of thecomponent and conform to a surface geometry of the component and asecond portion configured to be compressed onto a second side of thecomponent opposite the first side and conform to the surface geometry ofthe component, wherein the first and second portions are bonded to oneanother in a bonded region without bonding to the component.
 9. Thepacked component of claim 8, wherein the packing component captures morethan 25% of the perimeter and less than 50% of the surface area of thecomponent.
 10. The packed component of claim 8, wherein at least one ofthe first portion and the second portion include a cutout for receivingthe component.
 11. The packed component of claim 8, wherein the firstportion and the second portion are bonded together by an adhesive in thebonded region, and the adhesive includes at least one of water basedglue, hot-melt, non-scratching rubber latex, and dry pressure-sensitiveadhesive.
 12. The packed component of claim 8, wherein the component isglass.
 13. A method of packaging a component comprising: compressing afirst portion of a packing component onto a first side of a component;compressing a second portion of a packing component onto a second sideof the component, the second side opposite the first side; and bondingthe first portion to the second portion in a bonded area such thatneither the first portion nor the second portion are bonded to thecomponent.
 14. The method of claim 13, wherein the bonding isaccomplished by an adhesive, the adhesive including at least one ofwater based glue, hot-melt, non-scratching rubber latex, and drypressure-sensitive adhesive.
 15. The method of claim 13, wherein thebonding is accomplished by thermal or chemical bonding.
 16. The methodof claim 13, further comprising processing a starch-based biodegradablematerial to provide at least one of the first and second portions, suchthat the starch-based biodegradable material expands to provide pores orcavities.
 17. The method of claim 16, wherein the processing includesexpanding the starch-based biodegradable material to form pellets, andloosely attaching the pellets together to provides spaces between thepellets.
 18. The method of claim 16, further comprising adding aheat-expandable thermoplastic material to the biodegradable materialprior to the processing, to enhance properties of the processedbiodegradable material.
 19. The method of claim 16, wherein the pores orcavities allow for the compressing.
 20. The method of claim 16, whereinthe starch-based biodegradable material includes an amylose content ofgreater than 40% by weight, and wherein the amylose acts as a blowingagent which allows for the expansion.